Arctic Cat Prowler HDX Service Manual page 132

REMOVING
1. Remove the key from the ignition switch.
! WARNING
Always ensure that power cannot be inadvertently
applied to the ignition/ECM when working on the fuel
system. If the ignition switch is turned on, the electric
fuel pump will start and gas could be rapidly pumped
and spilled resulting in fire and severe injury.
2. Remove the seat, seat back, and seat base; then dis-
connect the negative battery cable.
3. Disconnect the electrical plug from the main harness;
then disconnect the gasline hose from the fuel pump.
4. Mark the fuel pump mounting and gas tank for
installing purposes; then remove the screws securing
the fuel pump to the gas tank and remove the fuel
pump.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
INSPECTING
AT THIS POINT
If the pump has failed earlier test and must be replaced,
proceed to INSTALLING.
1. Inspect the fuel screen and blow clean with low pres-
sure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower posi-
tion without force. If not, replace the fuel level sen-
sor assembly.
3. Test the fuel level sensor by connecting a multimeter
(A) to the fuel level sensor leads (B); then select
OHMS. The multimeter should show 5 ohms at full
fuel position (C) and 95 ohms at empty fuel position
(D).
NOTE: If readings are erratic, clean the resistor
wiper and resistor with clean alcohol and retest. If
still not correct, replace the fuel level sensor.
4. To replace the fuel level sensor, use the following
procedure.
A. Disconnect the two-wire connector (A); then
press the fuel level sensor toward the top of the
fuel pump to release it from the mounting slot
(B).
B. Engage the tabs (C) of the fuel level sensor into
the mounting slot (B) and press toward the bottom
of the fuel pump to latch in place; then connect
the two-wire connector (A).
INSTALLING
1. Place the fuel pump assembly into the gas tank with
a new gasket aligning the match marks; then secure
with the four screws. Tighten securely.
NOTE: It is important to install the fuel pump with
the correct orientation to ensure adequate float
lever clearance.
2. Connect the gasline hose to the fuel pump pipe and
secure with the hose clamp; then connect the electri-
cal plug to the main harness.
3. Connect the negative battery cable; then turn the
ignition switch to the ON position and verify that no
gas leaks are present, the pump runs for 2-3 seconds,
and the gas gauge reading is normal.
4. Start the engine to verify proper engine operation;
then shut off the engine and install the seat base, seat
back, and seat.
ATV2116
FI460A
129